Helmet



JY MY LEWIS Dec., 8, i931.

HELMET Filed March 20, 1930 2 Sheets-Sheet Y Y iNvENToR WITNESSES Dec. 8, lgg. I J, M` Ewls v 1,835,883

` HELMET I FiledMarCh 2o, 195o zsheefs-sheet 2' l 5g' jf WITNESSES Z1|;IVENTORl e Y@ Patented Dec. 8, 1931 UNITED STATES PATENT oFFlcE JOHN M. LEWIS, F EDGEWOOD BOROUGH, ALLEGHENY COUNTY, PENNSYLVANIA, AS-

SIGNOR T0 MINE SAFETY APPLIANCES COMPANY, OF PITTSBURGH, PENNSYLVANIA,

A CORPORATION 0F PENNSYLVANIA HELMET Application med Hatch 20, 1930. Serial No. 437,350.

The inve'ntion relates to protective headgear, particularly to safety helmets of thev endangered by falling objects, electric currents, or from other causes.

The object of the invention is to provide a molded safety headgear which is light 1n weight, rigid, strong enough to. withstand severe shock, is of non-conducting nature and has no exposed metal parts which may conduct electricity to the wearer, is'easily and economically made', and which 1s provided with a cushioned sweat bandwhich is renewable and adjustable to vary the shape and size of its head-engaging opening.

The invention is described in connection with the accompanying drawings which illustrate its preferred embodiment, and in which Fig. l is a plan view of a helmet showing the mode of construction; Fig. 2 a longitudinal section on line Il--II,y Fig. l; Fig. 3 an enlarged fragmentary view of the crown section shown in Fig. 2; and Figs. 4 and 5 plan views of elements used in the construction of the helmet.

The helmet provided according to the invention comprises crown and brim portions built up integrally from a plurality of layers of formable material embedded in and surrounded by a hard and non-conducting plastic material, thus providing a rigid, strong and sturdy structure. The term formable material asused herein includes not only readily formable fabric materials, such as textiles, leather and the like, but also those which may be shaped by special operations such as spinning, examples of which are sheet metal or vegetable fiber products. As used in the preferred embodiment, the form- `able materials are of a foraminous nature to use woven textiles, such as cloth, or wire screen, duck cloth being preferably used.

In the use of textile materials, each layer comprises a plurality of sectors adapted to lit together to form the proper shape, the various layers being disposed to overlap and break joints between sectors in adjacent layers. The sector-shaped pieces may be formed in a variety of ways, but in the preferred embodiment a sheet of fabric of suitable size is cut inwardly from the edge at an appropriate number of periphcrally spaced intervals to form a plurality of generally sector-shaped pieces joined to an uncut centrai body portion, the sectors extending from the edge of the brim'to a point materially within the crown. The sector construction makes it possible to shape the helmet quickly and easily Without the bulges or wrinkles which would result from the use of continuous single-piece layers. Although it is preferred tol use sector shapes of the type de-- scribed above, it will be understood that other shapes may also be used.

l/Vhen textile materials are used, the crown is preferably reinforced, most suitably by Various plastics are known which may be satisfactorily used in the construction of hats according to the invention, such as asphalt, or the plastics compounded from rubber, casein, or cellulose compounds, especially those made from cellulose acetate. It is preferred, however, to use plastics of the type comprising organic condensation products, this class'of plastics being generally termed synthetic resins or resinoids.v These materials are in initially plastic and moldable, but in general they become very hard, infusible, non-conducting, and insoluble in organic solvents, dilute acids and alkalies, when subjected to heat and pressure. Of these materials the best'known type, and the one preferably used, is that resulting from condcnsal other types may be used', of which t tion of phenol and formaldehyde although he phenolfurfural, and the urea-formaldehyde resinoids are examples.

The illustrative embodiment shown in the drawings represents a molded helmet of the type commonly worn by miners and firemen, which comprises a dome-shaped crown portion 1 and a brim 2 sloping downwardly and outwardly therefrom. In this preferred construction the helmet is formed fromtwo layers 3 of duck and an intermediate 'layer 4 of wire screen.

As shown in Fig. 4, the layers 3 are formed by cutting or slitting pieces of duck inward'- ly from the edge at a plurality of peripherally spaced points to form sector shaped pieces 3a joined at their inner ends to a generally circular central `body portion 5. These pieces or layers extend to the edge of brim 2', and preferably body portion 5 is relatively small, for example about 31/2 inches in .d1- ameter, for a helmet of average size. This construction insures smoothness ofthe layers when the hat is assembledinl a mold, and layers comprising about ten sectors are satisfactory. Other types of sector-shaped pieces may, of course, be used'.

The intermediate layer comprises a piece of wire screen 4 cut in the generally elliptical form shown in Fig. 5. When cut in this shape and of such size as to extend to a point short of the juncture of crown 1 and brim 2, the wires will adjust themselves when the crown is molded to form a smooth layer substantially free from any bulges. A 20- mesh screen formed from 0.013 gage steel wire affords a satisfactory reinforcement.

In the assembly of the hat, a layer 3 of duck cut as described is -placed in a mold of appropriate form and the sectors 3a are fitted together or slightly overlapped to form the crown and brim. Layer 4 of wire screen, previously shaped to conformto the crown 1n a form or die, is next lnserted in the crown portion ofthe mold,followed by another layer l3. The layers 3 are disposed to stagger the joints 6 between the sectors of the outer layer with respect to joints 7 of the inner layer, as shown in Fig. 1.

In order to provide adequate bonding between the Various layers, so as to prevent their separation under shock or other rough usage, the layers are cemented together during assembly and before the final plastic molding operation. To this end the screen is coated with a'suitable bonding material, such as the cements used in vulcanizing rubber. The screen and adjacent surfaces of layers 3 are coated with this material and l air dried before being placed in contact.

05 type referred to, it is presse After/the helmet has been .assembled in the manner just described, and the layers having been impregnated with a lastic, of the d in a heated mold. The structure of the helmet as thus constructed is shown in Fi 3, where thel layers are, shown surrounded y and impreg-y nated with molded resin 8 forming a dense, hard and strong materia v One feature of the headgear according to the invention resides in the provision of a removable and adjustable sweat band. As shown particularly in Fig. 2, a sweat band 9 of cloth or other suitable material is disposed within and spaced from the crown by spaced cushioning pads 10 disposed between the band and the crown. The spaces 11 between the ends of the pads permit free circulation of air inside lof the crown. IPreferably the band is bent back around the pads, as shown in Fig. 2. The band and pads are removably connected to the crown by a nonmetallic draw member 12 laced through holes 13, spaced around the crown and in the band and pads. The holes may be cut in the fabric prior to impregnation, or they may be made after the helmet is formed, and the draw member may consist of a leather thong, shoe string or the like.

The sweat band is easily Aremovable for replacement, and the size and shape ofv its head-receiving opening are readily changed. In the hat shown four pads are used. By

using thinner pads the opening may be cnlarged, or it may be reduced by means of thicker pads; and by disposing thick and thin pads in an appropriate manner, or by'shifting l the position of the pads, the opening may be shaped according to the outline of a particular individuals head. In the form shown, the material forming the sweat band is cut to provide a lining portion 14 gathered at its peak by a drawstring 15 in the customary manner. It will be understood, however, that different lining and sweat band materials may be used if desired.

The helmet may be provided with various accessories, such as a bracket for attachment of alight. This bracket may be, and preferably is, formed lby a non-conductor of electricity, such as leather, connected to the helmet so as not to carry electric current to the head of the wearer. This may suitably be accomplished as shown in Fig. 2. A leather strap 16 is connected at its lower end to the visor of the helmet, and its upper end is folded under to provide an. underlying flap 17 which is attached to the crown by rivets 18. In this manner the rivets are not exposed, and they cannot accidentally contact with electric wires. A bracket 19 is connected to strap 16 for receiving the usual` such rigid headgear, and reduces the number of sizes required to be manufactured.

:,esaaes The combination of cemented textile and reinforcing fabric layers provides maxlmuml strength and stabihty for rough usage, and to withstand puncture by fallin objects. A hat constructed as described wi l, for example, not be dented or injured by an 8-pound object fallin through 10 feet. Without the reinforcing ayer, the hat would be punctured by such a blow. Also, cementing of the layers adequately prevents their separation under shock.

Additional advantages result from the use of non-conducting fastening for the sweat band, which eliminates metal rivets and provides a fully non-conductin helmet, so as to totally eliminate danger o electrical shock when the helmet contacts with exposed wiring or other conductors carrying currents. This feature is retained even in the case of a helmet constructed of la ers of spinnable materials which are con uctors, the layers being wholly embedded ,in a non-conducting plastic. Furthermore, headgears provided according to the invention do not soften under heat and do not burn at any temperature toA which they are normally exposed, and

they are wholly inert to mine acid and moisture or other reagents which are frequently destructive of materials commonly used for this pur se.

Accor ing to the provisions of the patent statutes I have explained the princi le and` construction of my invention, and ave illustrated and described what I now consider to represent its best embodiment. However, I desire to have it understood that, within the scope of the appended claims, the invention may be practiced otherwise 'than as specilically illustrated and described.

I claim: l

1. A molded safety headgear comprising integrally formed rigid crown and br1m portions composed of molded plastic material interiorly reinforced b a plurality of superposed layers of formab e material, said layers being moldably embedded in said plastic to provide a unitary structure, and the headgear being hard, strong rigid, impervious and electrlcally non-con uctlng.

. 2. Aumolded safety helmet comprising integrally formed rigid crown and surrounding brim portions composed of molded plastic material interiorly reinforced by a plurality of superposed layers of textile material and a layer of wire fabric, said layers being moldably embedded in said' lasti'c to provide a unitary structure, and te helmet eing hard, strong, rigid, impervious and electrically non-conducting.

3. A molded safety helmet comprising integrally formed rigid crown and surrounding brim ortions composed of molded plastic material interiorly reinforced by a plurality of superposed layers of textile ma- 66 terial and a reinforcing ayer of wire fabric,

all of 'said layers being cemented together and moldably embedded in-said lastic to provide a unitary structure, and t e helmet bemg hard, strong, rigid, impervious and electrically non-conducting.

4. A molded safety helmet comprising integrally formed rigld crown and surrounding brim rtions composed of molded plastic material interiorl reinforced by a plurality of superposed ayers of formable material comprising fitted sector-shaped pieces disposed to break joints with those of another la er, said layersbeing moldably embedded in said plastic to provide a unitary structure, and the helmet being hard, strong, rigid, impervious and electrically non-conducting.

5. A molded safety helmet comprising integrally formed rigid crown and surrounding brim ortions composed of molded plastic material interiorly reinforced by a plurality of superposed layers of textile material comprising a plurality of sector-shaped pieces extending inwardlyifrom the edge of the brim and joined at a point materially within the crown to a central body portion, the sectors of one layer overlappln breaking joints with those of an 'adjacent layer, said layers being moldably embedded in said plastic to provide a unitary structure, and the helmet being hard, stron rigid, impervious and electrically non-con uctln and a sweatband removably disposed in sald Acrown and adjustable to vary the size and shape of vits head-engaging opening.

In testimony whereo I si m name.

' JOHN EWIS.

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